Combination hanger fastener

BACKGROUND AND SUMMARY

Hanger fasteners are provide to mount pipe fixtures and the like to building structures, such as walls and ceilings. Hanger fasteners are known in the art. These fasteners include a threaded or screw shank and an integrally or separately formed head with a typically axial, threaded opening suitable to support suspending pipe fixtures from the building structure. The shank portion of the fastener is fastened to the building structure, and a threaded rod is inserted into the threaded opening in the head, and the pipe fixture is suspended from the threaded rod.

Described in this application is a dual purpose hanger fastener for supporting fixtures, such as pipe fixtures, to a building structure. The dual-purpose hanger fastener includes a shank portion forming a first end and an integral head portion forming a second end. The shank portion is adapted, typically by threads, to engage and fasten the hanger fastener to a building structure. The head portion of the hanger fastener includes a cross-thread opening and an axial thread opening extending into the head, each adapted to receive a support member such as a threaded rod. The axial opening extends to a depth not less than one-thirty-second inch from the cross-thread opening and may be to a depth between one-fourth and one-thirty-second of an inch from the cross-thread opening. The support member enables the hanger fastener to support a pipe fixture or the like either by the cross-thread opening or the axial opening of the fastener head within narrow space typically available for these purposes in a building structure.

In certain embodiments, the first shank portion of the hanger fastener may be threaded so the shank portion can engage the building structure by threading the shank into the structure. In an embodiment, a portion of the head includes a drive section to engage a tool to permit the shank portion of the hanger fastener to be driven into a building structure by the tool. This drive portion of the head may be, for example, a hexagon.

In the same or another embodiment, the shank portion of the hanger fastener may include a lead self-drilling portion to enable the hanger fastener to be driven into a building structure without first forming a pilot hole. In addition, the head portion of the fastener hanger adjacent the cross-thread opening may be counter-sunk to enable a support member to be more easily guided into the cross-thread opening. The axial and cross-thread openings of the head portion may be threaded to receive the support member, such as a threaded rod.

Also disclosed in this application is a method of making a dual purpose hanger fastener for supporting a fixture from a building structure. The method includes the steps of forming a threaded shank portion as a first end portion, forming a head portion as a second end portion with a cross-thread opening, and forming an axial opening in the head portion extending into the head portion to at least one-thirty-second of an inch from the cross-thread opening. The threaded shank portion is adapted to be threaded into a building structure and the cross-thread opening and axial opening adapted to receive a threaded rod.

In some embodiments of this method there may be an additional step of forming a counter sink portion in the head portion adjacent the cross-thread opening to guide a support member into the cross-thread opening. In this or another embodiments, a drive portion of the head may be formed with a hex profile and/or the threaded shank may include a self drilling lead to assist in driving the hanger fastener into a building structure. The axial and cross-thread openings e.g. three-eighth inch diameter, in the portion of the hanger fastener may be threaded to receive the threaded rod. The cross-thread opening may be substantially perpendicular to the axial opening of the head portion of the hanger fastener.

Also disclosed in this application is a method of assembling a pipe fixture or the like to a building structure with a hanger fastener. The method includes the steps of assembling a hanger fastener with a cross-thread opening and an axial opening extending into the head to a depth not less than one-thirty-second inch from the cross-thread opening, threading a threaded shank portion of the hanger fastener into a building structure, securing a support member to an axial opening or cross-thread opening of the head portion of the hanger fastener, and securing a fixture to the support member. The dual purpose hanger fastener may be assembled with a threaded shank adapted to be threaded into a building structure. The head includes a cross-thread opening and an axial opening, both adapted to receive a support member to support a pipe fixture or the like by the hanger fastener from a building structure.

In some embodiments of the method the first end portion is assembled with a self drilling lead portion on the shank portion. In this or other embodiment a portion of the head of the hanger fastener may be assembled with a drive portion adapted to receive a driving tool. The method may include the additional step of attaching a driving tool to this drive portion of the head portion of the hanger fastener to enable the shank portion of the hanger fastener to be driven into the building structure without a pilot hole. The dual purpose hanger fastener may include a counter-sink portion adjacent the cross-thread opening of the head portion to enable a support member to be guided into the cross-thread opening.

BRIEF DESCRIPTION OF DRAWINGS

<figref idref="DRAWINGS">FIG. 1</figref> is a perspective view of a hanger.

<figref idref="DRAWINGS">FIG. 2</figref> is a side cutaway view of a hanger fastener shown in <figref idref="DRAWINGS">FIG. 1</figref>, mounting a pipe fixture to a building structure according to a first arrangement.

<figref idref="DRAWINGS">FIG. 3</figref> is a side cutaway view of a hanger fastener shown in <figref idref="DRAWINGS">FIG. 1</figref>, mounting a pipe fixture to a building structure according to a second arrangement.

<figref idref="DRAWINGS">FIG. 4</figref> is a side cutaway view of a hanger fastener shown in <figref idref="DRAWINGS">FIG. 1</figref>, mounting a pipe fixture to a building structure according to a third arrangement.

<figref idref="DRAWINGS">FIG. 5</figref> is a side cutaway view of a hanger fastener shown in <figref idref="DRAWINGS">FIG. 1</figref>, mounting a pipe fixture to a building structure according to a fourth arrangement.

<figref idref="DRAWINGS">FIG. 6</figref> is a side cutaway view of a hanger fastener shown in <figref idref="DRAWINGS">FIG. 1</figref>, mounting a pipe fixture to a building structure according to a fifth arrangement.

<figref idref="DRAWINGS">FIG. 7</figref> is a side cutaway view of a hanger fastener shown in <figref idref="DRAWINGS">FIG. 1</figref>, mounting a pipe fixture to a building structure according to sixth arrangement.

<figref idref="DRAWINGS">FIG. 8</figref> is a side cutaway view of a hanger fastener according to one arrangement.

<figref idref="DRAWINGS">FIG. 9A</figref> is an end view of a hanger fastener according to a second arrangement.

<figref idref="DRAWINGS">FIG. 9B</figref> is an end view of a hanger fastener according to a third arrangement.

<figref idref="DRAWINGS">FIG. 9C</figref> is an end view of a hanger fastener according to a fourth arrangement.

<figref idref="DRAWINGS">FIG. 9D</figref> is an end view of a hanger fastener according to a fifth arrangement.

<figref idref="DRAWINGS">FIG. 10A</figref> is an enlarged view of the end of a hanger fastener according to a first arrangement.

<figref idref="DRAWINGS">FIG. 10B</figref> is an enlarged view of the end of a hanger fastener according to a second arrangement.

<figref idref="DRAWINGS">FIG. 10C</figref> is an enlarged view of the end of a hanger fastener according to a third arrangement.

<figref idref="DRAWINGS">FIG. 11A</figref> is a cutaway view of the cross-thread opening of a hanger fastener according to a first arrangement.

<figref idref="DRAWINGS">FIG. 11B</figref> is a cutaway view of the cross-thread opening of a hanger fastener according to a second arrangement.

<figref idref="DRAWINGS">FIG. 11C</figref> is a cutaway view of the cross-thread opening of a hanger fastener according to a third arrangement.

<figref idref="DRAWINGS">FIG. 12</figref> is an enlarged view of the interface between the head portion and the shank portion of a hanger fastener according to a first arrangement.

DETAILED DESCRIPTION

A dual purpose hanger fastener for use in attaching pipe fittings and the like in confined areas of a building structure is provided in <figref idref="DRAWINGS">FIG. 1</figref>. The hanger fastener <b>100</b> includes a head portion <b>102</b> and a threaded shank portion <b>104</b> integrally attached thereto and adapted to be threaded into a building structure. The threaded shank portion <b>104</b> includes an end <b>106</b> adapted to drive the hanger fastener <b>100</b> into a building structure. The head portion <b>102</b> includes an axial opening <b>108</b> extending into the head portion <b>102</b> and a cross-threaded opening <b>110</b> extending across the head portion <b>102</b>. The cross-thread opening <b>110</b> may be provided with a counter-sink portion <b>112</b>, counter-bore, or other recess to assist in guiding a threaded rod into engagement with the cross-thread opening <b>110</b>. The head portion may also include at an end, opposite the threaded shank portion <b>104</b>, a driving portion <b>114</b> adapted to receive a tool for driving the threaded shank portion <b>104</b> into a building structure. Building structure is used here in a broad sense to mean any structure of a commercial or residential building or construction site where hanger fasteners may be used to support pipe fixtures, cable and the like. A ceiling or wall assembly is available to enable plumbing, wiring and other support services to provided through the building.

The above-described dual purpose hanger fastener for use in attaching and running pipe, cable and the like through a building structure may be utilized as desired. According to the presently disclosed method, where <figref idref="DRAWINGS">FIGS. 2-6</figref> are representative illustrations, the hanger fastener <b>100</b> may be attached to a building structure <b>116</b>, such as a ceiling, wall or floor. The hanger fastener <b>100</b> may be attached to structural components—such as studs or joists—or other components—such as drywall or insulation—of the building structure. The hanger fastener <b>100</b> is attached by securing a tool to the driving portion <b>114</b> of the head <b>102</b> and rotating the hanger fastener <b>100</b> to drive the shank portion <b>104</b> into the building structure <b>116</b>. The shank portion <b>104</b> may include a self-drilling lead at the end <b>106</b> to enable the threaded shank <b>104</b> to be driven into the building structure <b>116</b> and support the hanger fastener.

Once the hanger fastener <b>100</b> has been secured to the building structure <b>116</b> a support member (generally designated <b>118</b>) may next be attached to the hanger fastener <b>100</b> to secure in place a pipe, cable, wiring, or other utility component <b>120</b>. The support member <b>118</b> preferably includes a threaded rod that may be threaded into either or both of the axial opening <b>108</b> and the cross-thread opening <b>110</b>. Attached to the support member <b>118</b> may be the utility component <b>120</b> or further structure, such as a strap <b>122</b>, for supporting the utility component <b>120</b>.

The head portion <b>102</b> of the hanger fastener <b>100</b> is provided of sufficient length to receive both the axial opening <b>108</b> and the cross-thread opening <b>110</b> and provide sufficient thread engagement in both of the openings to enable utility components <b>120</b> to be safely hung from the hanger fastener <b>100</b>. Support hangers <b>118</b> may be provided with an axial <b>108</b> and cross-thread <b>110</b> openings of for example a ⅜″ (9.5 mm) diameter. The head portion <b>102</b> may have a length dimension between 1.1 and 1.5″ (28-38 mm) to accommodate the cross-thread opening <b>110</b> and allow the axial opening <b>108</b> to extend into the head <b>102</b> to a sufficient depth to enable sufficient thread engagement between the support hanger <b>118</b> and head portion <b>102</b> to support the utility component <b>120</b>, and without the axial opening <b>108</b> intersecting of inhibiting to the cross-thread opening. The axial opening <b>108</b> preferably extends to not less than 1/32″, e.g. 1/16″ (1.6 mm); of the cross-thread opening <b>110</b>.

<figref idref="DRAWINGS">FIG. 2</figref> illustrates one arrangement of support members <b>118</b> using the hanger fastener <b>100</b> of the present disclosure. In this arrangement, the hanger fastener <b>100</b> has been secured to a building structure <b>116</b>, here a ceiling, by driving the threaded shank portion <b>104</b> into the ceiling <b>116</b> and rotating the hanger fastener <b>100</b> to thread the shank portion to a desired depth. A first support member <b>118</b>A is threaded into or through the cross-thread opening <b>110</b> and may connect to another hanger fastener <b>100</b>, support a utility component, allowing wires to be hung from the support member <b>118</b>A, or provide additional structural support between hangers. A second support member <b>118</b>B may be threaded into the axial opening <b>108</b> to support a utility component <b>120</b>, wiring cables, or other utilities.

<figref idref="DRAWINGS">FIGS. 3-4</figref> illustrate additional methods of using the dual-purpose hanger fastener <b>100</b>. In these figures the hanger fastener <b>100</b> is attached to a ceiling building structure <b>116</b> and a support member <b>118</b> for supporting a utility component <b>120</b> is selectively attached either to the axial opening <b>108</b> as shown in <figref idref="DRAWINGS">FIG. 3</figref> or to the cross-thread opening <b>110</b> as shown in <figref idref="DRAWINGS">FIG. 4</figref>, e.g. a tie-rod stabilizer. This improved hanger fastener allows a single size to be maintained in inventory and used for various different types of support members <b>118</b>. In either of these arrangements the utility component <b>120</b> may be attached to the opposite end of the support member <b>118</b> and supported permanently in place by the hanger fastener.

<figref idref="DRAWINGS">FIG. 5</figref> illustrates another method of using the hanger fastener <b>100</b>. In this arrangement, a plurality of hanger fasteners <b>100</b> may be provided and secured to a building structure <b>116</b> such as a ceiling. Support members <b>118</b>, such as threaded rods, are then inserted into the axial openings <b>108</b> of the hanger fasteners <b>100</b> and extend downwards and away from the building structure <b>116</b>. An utility component <b>120</b> or other structure may be supported between the support members <b>118</b>. The utility component <b>120</b> may be secured to the support members <b>118</b> by known means such as nuts, threaded openings, hooks or other structure.

<figref idref="DRAWINGS">FIG. 6</figref> illustrates another method of using the hanger fastener <b>100</b>. In this arrangement, the hanger fastener <b>100</b> is secured to a building structure <b>116</b> such as a wall and a support member <b>118</b>, such as a threaded rod, is inserted into the cross-thread opening <b>110</b>. The support member <b>118</b> extends from to the building structure <b>116</b> and a utility component <b>120</b> such as a pipe fitting is attached by support member <b>118</b> to the hanger fastener <b>100</b>. This arrangement allows utility components <b>120</b> such as pipe fittings and the like to be attached against a wall without securing the hanger fastener <b>100</b> to a ceiling.

An additional method of attaching the hanger fastener <b>100</b> to a building structure <b>116</b> is illustrated in <figref idref="DRAWINGS">FIG. 7</figref>. In this arrangement the building structure <b>116</b> comprises a beam or other similar structure that may be capable of supporting the hanger fastener <b>100</b> by thread engagement or the member may be unsuitable to self-threading. Rather than threading the shank portion <b>104</b> into the building structure <b>116</b>, a pilot hole may be provided in the building structure <b>116</b>. The shank portion <b>104</b> is then passed through the pilot hole and secured by means of a nut <b>122</b> or other hardware. The hanger fastener <b>100</b> is thereby supported to the structure <b>116</b> by the lock nut <b>122</b>. Other means for anchoring the shank portion <b>104</b> are also contemplated, including wall anchors, tapped holes, or other structure for securing a support member <b>118</b> to a structure <b>116</b>. This figure further illustrates one method of attaching a pipe or the like by the hanger fastener <b>100</b> to a building structure. In this embodiment, a support member <b>118</b> is secured to the axial opening <b>108</b> of the hanger fastener <b>100</b> and extends to a utility component <b>120</b> such as a strap <b>120</b>. The strap <b>120</b> may be secured to the support member <b>118</b> by means of a nut which may be welded to the strap <b>120</b>. A pipe may be supported by the strap <b>120</b> and thereby remain supported from the building structure <b>116</b> by hanger fastener <b>100</b>.

<figref idref="DRAWINGS">FIG. 8</figref> is a side cutaway view of the dual hanger fastener <b>100</b> illustrated in <figref idref="DRAWINGS">FIG. 1</figref>. Various alternative arrangements of the dual hanger fastener <b>100</b> are shown in <figref idref="DRAWINGS">FIGS. 9-13</figref>. <figref idref="DRAWINGS">FIGS. 9A-D</figref> are end views of the head portion <b>102</b> taken along line <b>9</b>-<b>9</b> in <figref idref="DRAWINGS">FIG. 8</figref> and illustrate various arrangements of the driving portion <b>114</b>. <figref idref="DRAWINGS">FIGS. 10A-C</figref> are enlarged side views of the threaded shank portion <b>104</b> taken by section <b>10</b> in <figref idref="DRAWINGS">FIG. 8</figref> and illustrating various arrangements of the end <b>106</b>. <figref idref="DRAWINGS">FIGS. 11A-F</figref> are enlarged cutaway side views of the head portion <b>102</b> indicated by portion <b>11</b> in <figref idref="DRAWINGS">FIG. 8</figref> and showing various alternative arrangements of the head portion <b>102</b> and cross-thread opening <b>110</b>. <figref idref="DRAWINGS">FIG. 12</figref> is an enlarged cutaway side views of the head portion <b>102</b> and threaded shank portion <b>104</b> in <figref idref="DRAWINGS">FIG. 8</figref> and show various alternative arrangements of the intersection between the head portion <b>102</b> and threaded shank portion <b>104</b>.

<figref idref="DRAWINGS">FIGS. 9A-D</figref> are end views of the hanger fastener <b>100</b> taken along line <b>9</b>-<b>9</b> in <figref idref="DRAWINGS">FIG. 8</figref>. These views illustrate various embodiments of the driving portion <b>114</b> of the hanger fastener <b>100</b> and are designed to correspond to a tool.

<figref idref="DRAWINGS">FIG. 9A</figref> illustrates a first embodiment wherein the driving portion <b>114</b> comprises a hexagonal drive portion adapted to receive a wrench, or other type of external driver, including without limitation: high torque, multi-lobe, square, hexagonal, or other type of driver. The driving portion <b>114</b> may have a width of ½″ (12.7 mm) for receiving a wrench or driver.

<figref idref="DRAWINGS">FIG. 9B</figref> illustrates a second embodiment wherein the driving portion <b>114</b> is substantially cylindrical and includes opposite planar sides adapted to receive a wrench or the like. In this arrangement, the driving portion <b>114</b> may have a width along the head portion <b>102</b> sufficient to receive a wrench or other driver.

<figref idref="DRAWINGS">FIG. 9C</figref> illustrates a third embodiment wherein the driving portion <b>114</b> comprises a recessed hexagonal drive portion adapted to receive a hexagonal driver, such as an Allen wrench. The recessed hexagonal portion is preferably centered on the axial opening <b>108</b> and extends to a depth of approximately ⅛″ (3.2 mm) for receiving the wrench. Other arrangements of the driving portion <b>114</b> are contemplated for receiving various types of internal drives, including without limitation: multi-lobular drives, square drives, hexagonal drives, star drives, spline, or one-way drives.

<figref idref="DRAWINGS">FIG. 9D</figref> illustrates a fourth embodiment wherein the driving portion <b>114</b> comprises a recessed slot for receiving a screw driver, such as a flat or Phillips-type screw driver.

The embodiments illustrated in <figref idref="DRAWINGS">FIGS. 9A-D</figref> are intended to present various alternative examples. Various other arrangements for accommodating various drivers including square drives, multi-lobular drives, or other types of arrangements are also contemplated.

<figref idref="DRAWINGS">FIGS. 10A-C</figref> are side views of the threaded shank portion <b>104</b> of the hanger fastener <b>100</b> with particular emphasis on the end <b>106</b>.

According to the embodiment illustrated in <figref idref="DRAWINGS">FIG. 10A</figref> the end <b>106</b> comprises a self-drilling lead tip. This self-drilling lead provides for driving the hanger fastener into a building structure without a preformed pilot hole to allow for efficient thread engagement of the threaded shank portion <b>104</b> with the building structure <b>116</b>. A second embodiment is illustrated in <figref idref="DRAWINGS">FIG. 10B</figref>. According to this second embodiment, the threaded shank portion <b>104</b> is a tapered shank at the end <b>106</b> that is a self-threading lead suitable for attachment to wood. Illustrated in <figref idref="DRAWINGS">FIG. 10C</figref> is a third embodiment where the shank portion has an untapered shank and threads extending the length of the shank portion <b>104</b>, commonly referred to as a machine screw thread. This type of shank portion involves a pilot hole and a nut or tapped hole to securely fasten the hanger fastener <b>100</b> therein. The embodiments illustrated in <figref idref="DRAWINGS">FIGS. 10A-C</figref> are intended to present various alternatives and are not intended to be limiting. Various other end <b>106</b> arrangements are also contemplated.

<figref idref="DRAWINGS">FIGS. 11A-F</figref> are cutaway views of the head portion <b>102</b> illustrating various embodiments of the cross-thread opening <b>110</b>.

According to the embodiment illustrated in <figref idref="DRAWINGS">FIG. 11A</figref>, the cross-threaded opening <b>110</b> extends through the width of the head portion <b>102</b>. The axial opening <b>108</b> extends from an end of the head portion <b>102</b> towards the cross-thread opening <b>110</b> to not less than 1/32 of an inch and not intersect with the cross-thread opening <b>110</b>. A concave counter-sink portion <b>112</b> is centered on the opening to the cross-thread opening <b>110</b> and provided to guide a threaded rod into the cross-thread opening <b>110</b>. According to the illustrated embodiment, the cross-thread opening <b>110</b> and the axial opening <b>108</b> are threaded to receive a threaded rod or the like.

An alternative embodiment is illustrated in <figref idref="DRAWINGS">FIG. 11B</figref>. According to this arrangement, the cross-thread opening <b>110</b> extends through the width of the head portion <b>102</b> and does not include a taper or counter-sink portion for directing a threaded rod into the cross-thread opening <b>110</b>. As with the embodiment illustrated in <figref idref="DRAWINGS">FIG. 11A</figref>, the cross-thread opening <b>110</b> of this embodiment is threaded to receive a threaded rod or the like.

Another alternative embodiment is illustrated in <figref idref="DRAWINGS">FIG. 11C</figref>. According to this arrangement a tapered counter-sink portion <b>112</b> is provided in lieu of the concave counter-sink portion <b>112</b> illustrated in <figref idref="DRAWINGS">FIG. 11A</figref>. The tapered counter-sink portion <b>112</b> similarly guides a threaded rod into the cross-thread opening <b>110</b>. As with previous embodiments, the axial opening <b>108</b> is spaced from the cross-thread opening <b>110</b> by at least 1/32″ (0.8 mm). The cross-thread opening <b>110</b> is threaded to receive a threaded rod or the like.

As described above, the hanger fastener <b>100</b> includes a head portion <b>102</b> and threaded shank <b>104</b>. One method of attaching the threaded shank portion <b>104</b> to the head portion is provided in <figref idref="DRAWINGS">FIG. 12</figref>.

<figref idref="DRAWINGS">FIG. 12</figref> illustrates an embodiment of the hanger fastener <b>100</b> where the threaded shank portion <b>104</b> is integrally formed with the head portion <b>102</b>. According to this integral formation, the head portion <b>102</b> and threaded shank portion <b>104</b> are a single piece construction.

Also described in this application is a novel method for making a dual purpose hanger fastener for a fixture or the like. The novel method comprises a series of steps described as follows.

First, a shank portion is formed as a first end portion of a hanger fastener. The shank portion is adapted to engage a building structure as described above with reference to <figref idref="DRAWINGS">FIGS. 10A-C</figref>.

Second, a second portion of the hanger fastener is formed into a head portion. The head portion is formed with a cross-thread opening extending through the head portion and is adapted to receive a support member, such as a threaded rod.

Third, an axial opening is formed in the second end portion of the head portion. The axial opening extends into the head portion to not less than 1/32″ (0.8 mm) from the cross-threaded opening. The axial opening is likewise adapted to receive a support member, such as a threaded rod. The gap between end axial opening in the head portion and the cross-thread opining is at least 1/32″ (0.8 mm) and is generally between one-quarter inch and one-thirty-second inch to inhibit interference between the axial opening and the cross-thread opining yet provide a hanger fastener that can be useful in the limited space generally available for use in running utilities, wiring cable and the like in building structures.

The above described embodiments are intended to be exemplary embodiments of the claimed invention. These embodiments are not intended to be limiting as those having skill in the art will recognize that various other embodiments will be obvious from the foregoing. These alternatives are intended to be within the scope of the invention. Any limitations to the claimed invention will be in the claims as allowed.